Mattress with segmented foam core

Abstract

A mattress including a support core formed from a high-density foam, one or more comfort layers, and a mattress cover is disclosed. The support core includes a top face, a bottom face, a first lateral face, and a second lateral face with a cranial flexion channel, a caudal flexion channel, and at least one stress relief channel position on the bottom face. The cranial flexion channel and the caudal flexion channel are each formed from gaps having a width of 0.5 to 2.5 inches and the at least one stress relief channel is formed from a cut in the high-density foam extending between the first lateral face and the second lateral face. The cranial flexion channel, the caudal flexion channel, and the at least one stress relief channel each have a depth leaving a residual thickness of intact high-density foam of 1 inch to 3 inches aligned with each channel.

What is claimed is: 
     
         1 . A mattress comprising:
 a support core formed from a high-density foam, wherein:
 the support core comprises a top face, a bottom face, a first lateral face, and a second lateral face, 
 the bottom face comprises a cranial flexion channel positioned proximal a first end of the mattress, a caudal flexion channel positioned proximal a second end of the mattress, and at least one stress relief channel position between the cranial flexion channel and the caudal flexion channel, 
 the cranial flexion channel being formed from a gap having a width of 0.5 to 2.5 inches in the high-density foam extending between the first lateral face and the second lateral face of the support core and to a cranial channel depth such that the high-density foam has a residual thickness of 1 inch to 3 inches aligned with the cranial flexion channel, 
 the caudal flexion channel being formed from a gap having a width of 0.5 to 2.5 inches in the high-density foam extending between the first lateral face and the second lateral face of the support core and to a caudal channel depth such that the high-density foam has a residual thickness of 1 inch to 3 inches aligned with the caudal flexion channel, 
 the at least one stress relief channel being formed from a cut in the high-density foam extending between the first lateral face and the second lateral face of the support core and to a stress relief channel depth such that the high-density foam has a residual thickness of uncut high-density foam of 1 inch to 3 inches aligned with the at least one stress relief channel; 
   one or more comfort layers positioned adjacent the top face of the support core; and   a mattress cover encasing the support core and the one or more comfort layers.   
     
     
         2 . The mattress of  claim 1 , wherein the support core comprises a maximum thickness of 6 inches to 8 inches. 
     
     
         3 . The mattress of  claim 1 , wherein the width of the gaps forming the cranial flexion channel and the caudal flexion channel are in the range of 1.0 to 2.0 inches. 
     
     
         4 . The mattress of  claim 1 , wherein the cranial flexion channel is positioned 12 inches to 24 inches from the first end of the mattress. 
     
     
         5 . The mattress of  claim 1 , wherein the caudal flexion channel is positioned 12 inches to 24 inches from the second end of the mattress. 
     
     
         6 . The mattress of  claim 1 , wherein one of the at least one stress relief channels is positioned 6 inches to 18 inches from the cranial flexion channel. 
     
     
         7 . The mattress of  claim 1 , wherein one of the at least one stress relief channels is positioned 6 inches to 18 inches from the caudal flexion channel. 
     
     
         8 . The mattress of  claim 1 , wherein the support core comprises at least two stress relief channels. 
     
     
         9 . The mattress of  claim 8 , wherein one of the at least two stress relief channels is positioned 6 inches to 18 inches from the cranial flexion channel and one of the at least two stress relief channels is positioned 6 inches to 18 inches from the caudal flexion channel. 
     
     
         10 . The mattress of  claim 1 , wherein the high-density foam comprises polyurethane. 
     
     
         11 . The mattress of  claim 1 , wherein the mattress cover comprises a quilted panel having a ticking material, a backing material, and a support material having a degree of compression provided between the ticking and backing materials, the ticking material, the support material and the backing material all being quilted together. 
     
     
         12 . The mattress of  claim 11 , wherein the ticking material comprises an upholstery ticking. 
     
     
         13 . The mattress of  claim 11 , wherein the backing material comprises a non-woven fabric. 
     
     
         14 . The mattress of  claim 11 , wherein the support material comprises a polymer foam or fill layer. 
     
     
         15 . The mattress of  claim 1 , wherein the one or more comfort layers comprise a panel of foam, microcoils, a bat of natural fiber, or their combinations. 
     
     
         16 . The mattress of  claim 15 , wherein one or more of the one or more comfort layers comprises a panel of foam, the panel of foam formed from one or more of a latex foam, a cooling foam, an open-celled foam, and a memory foam. 
     
     
         17 . The mattress of  claim 16 , wherein the mattress includes a memory foam layer. 
     
     
         18 . The mattress of  claim 17 , wherein the memory foam layer is a polyurethane foam with a bulk density ranging from about 2.6 to about 4.0 pounds per cubic foot. 
     
     
         19 . The mattress of  claim 16 , wherein the mattress includes a cooling foam layer. 
     
     
         20 . The mattress of  claim 16 , wherein the mattress includes an open-celled foam layer.